I am currently designing a product for use in the automotive industry, and it will be used externally to the vehicle. I am at the awkward stage of trying to combine PCB design with product packaging/external/mechanical design considerations. External packaging will most likely be molded and reasonably thick (2-3mm at least) ABS plastic, with cut outs or recesses for human interaction mechanisms like buttons, switches, and/or some LED indicators.
The design is quite space limited, think about the size of an old VHS cassette tape but not quite a long (aiming for about 120mm x 120mm x 40mm external dimensions) and will end up being most likely a double-sided PCB with heavy population of components.
I have been looking at trying to use everything PCB mount, so that wire harnesses and assembly process during manufacture is a painless as possible. I feel bad for the Chinese factory workers..
Even though it's not directly a PCB mount device, I was thinking of using a SPST push button for on/off such as this one:
or a rocker switch on the side of the case like this one: Rocker switch
But as you can see, it has these annoying "snap in" or "quick connect" terminals on them, making it both hard for me to mount this directly to a PCB, and even worse for right-angle mounting which is preferable.
Does anyone have recommendations/resources for how to design PCB footprints to accommodate these kind of "pins", or can recommend a cost-effect way to mount or connect these parts?
My easy alternative is a right angle PCB slide switch, but it may not be robust enough for the elements and possible heavy physical abuse from random "Consumers", who might buy automotive style products. I have looked at products like this:
I am trying to avoid the really handy right angle through hole "toggle switch" components like this one: fancy toggle switch because they seem a little expensive, and their metal lever is often too long and will be a nuisance. Help!
Also while i'm asking about manufacturing/product design, how can I incorporate surface mount LEDs properly when trying to make them visible to the outside world? Using plastic light tubes? Just little clear plastic windows?